5000VG7S Series. INSTRUCTION MANUAL High-Performance, Vector Control Inverter. CT Use (150%)

Transcription

1 5000VG7S Series INSTRUCTION MANUAL High-Performance, Vector Control Inverter CT Use (150%) 200V Series 400V Series 0.75kW/FRN0.75VG7S-2 3.7kW/FRN3.7VG7S-4 ~90kW/FRN90VG7S-2 ~400kW/FRN400VG7S-4 710kW/FRN710BVG7S-4DC 800kW/FRN800BVG7S-4DC VT Use (110%) 200V Series 400V Series 1.5kW/FRN0.75VG7S kw/frn3.7vg7s-4 ~110kW/FRN90VG7S-2 ~710kW/FRN630VG7S-4 HT Use (200%/170%) 200V Series 400V Series 3.7kW/FRN3.7VG7S kw/frn3.7vg7s-4 ~55kW/FRN55VG7S-2 ~55kW/FRN55VG7S-4 CAUTION Read all operating instructions before installing, connecting (wiring), operating, servicing, or inspecting the inverter. Ensure that this instruction manual is made available to the final user of the inverter. Store this manual in a safe, convenient location. The product is subject to change without prior notice. Fuji Electric FA Components & Systems Co.,Ltd. INR-HF51306 d-e

2 Instructions Thank you for purchasing our FRENIC5000VG7S series inverter. This product is used to drive a 3-phase induction motor at variable speed. As incorrect use of this product may result in personal injury and/or property damage, read all operating instructions before using. As this manual does not cover the use of function cords and option cards, etc., refer to FRENIC5000VG7S Users Manual. Safety Instructions Read this manual carefully before installing, connecting (wiring), operating, servicing, or inspecting the inverter. Familiarize yourself with all safety features before using the inverter. In this manual, safety messages are classified as follows: Improper operation may result in serious personal injury or death. Improper operation may result in slight to medium personal injury or property damage. Situations more serious than those covered by CAUTION will depend on prevailing circumstances. Always follow instructions. Instructions on use This inverter is designed to drive a 3-phase induction motor and is not suitable for a single-phase motor or others, as fire may result. This inverter may not be used (as is) as a component of a life-support system or other medical device directly affecting the personal welfare of the user. This inverter is manufactured under strict quality control standards. However, safety equipment must be installed if the failure of this device may result in personal injury and/or property damage. There is a risk of accident. Instructions on installation Mount this inverter on an incombustible material such as metal. There is a risk of fire. Do not place combustible or flammable material near this inverter, as fire may result. The inverter housed in IP00 (18.5kW or over) should be installed in a place where no one can touch it easily. Electric shock or injury may result. 0-1

3 Do not hold or carry this inverter by the surface cover. Inverter may be dropped causing injury. Ensure that the inverter and heat sink surfaces are kept free from foreign matter (lint, paper dust, small chips of wood or metal chips), as fire or accident may result. Do not install or operate a damaged inverter or an inverter with missing parts, as injury may result. When changing installation bracket position, use the attached screws, as injury may result. Instructions on wiring Confirm that the phases and rated voltage of this product match those of the AC power supply, as injury may result. Do not connect the AC power supply to the output terminals (U, V, and W), as injury may result. Do not connect a braking resistor directly to the DC terminals (P(+) and N( )), as fire may result. When using DC power input, ensure that the fan power switching connector (CN RXTX) is correctly engaged in the inverter as a trouble may occur. When using DC power input of 18.5kW or larger inverter, be sure to connect AC power to terminals R0 and T0 for a power supply of fan as a trouble may occur. Ensure that the noise generated by the inverter, motor, or wiring does not adversely affect peripheral sensors and equipment, as accident may result. 0-2

4 Instructions on operation Be sure to install the surface cover before turning on the power (closed). Do not remove the cover while power to the inverter is turned on. Electric shock may occur. Do not operate switches with wet hands, as electric shock may result. When the retry function is selected, the inverter may restart automatically after tripping. (Design the machine to ensure personal safety in the event of restart) Accident may result. When the torque limiting function is selected, operating conditions may differ from preset conditions (acceleration/deceleration time or speed). In this case, personal safety must be assured. Accident may result. As the STOP key is effective only when a function setting has been established, install an emergency switch independently, and when an operation via the external signal terminal is selected, the STOP key on the KEYPAD panel will be disabled. Accident may result. As operations start suddenly if alarm is reset with a running signal input, confirm that no running signal is input before resetting alarm. Accident may result. When an alarm is activated, the motor coasts. If the motor needs to be stopped in such a case, install a brake to the machine with the motor. Accident may result. If AUTO RESTART is selected in the restart mode after momentary power failure (function code F14), the inverter restarts automatically starting the motor rotation when the power is recovered. Accident may result. When the tuning (function code H01) is started, the motor, machine or equipment starts and stops repeatedly. Ensure safety before performing tuning. Accident may result. If the user set the function codes wrongly or without completely understanding this user s manual, the motor may rotate with a torque or at a speed not permitted for the machine. Accident or injury may result. Do not touch inverter terminals when energized even if inverter has stopped. Electric shock may result. Do not start or stop the inverter using the main circuit power. Failure may result. Do not touch the heat sink or braking resistor because they become very hot. Burns may result. As the inverter can set high speed operation easily, carefully check the performance of motor or machine before changing speed settings. Injury may result. Do not use the inverter braking function for mechanical holding. Injury may result. During pre-excitation, the speed adjuster does not function and the motor may be rotated by load disturbance. When using pre-excitation, therefore, also use the mechanical brake. Injury may result. If improper data is set at the function code related with speed adjuster as in the case of setting high gain abruptly, the motor may hunt. Injury may result. 0-3

5 Instructions on maintenance, inspection, and replacement Wait a minimum of five minutes (15kW or less) or ten minutes (18.5kW or more) after power has been turned off (open) before starting inspection. (Also confirm that the charge lamp is off and that DC voltage between terminals P(+) and N( ) does not exceed 25V.) Electric shock may result. Only authorized personnel should perform maintenance, inspection, and replacement operations. (Take off metal jewelry, such as watches and rings. Use insulated tools.) Electric shock or injury may result. Instructions on disposal Treat as industrial waste when disposing it. Injury may result. Other instructions Never modify the product. Electric shock or injury may result. General Instructions Although figures in this manual may show the inverter with covers and safety screens removed for explanation purposes, do not operate the device until all such covers and screens have been replaced. 0-4

6 Warning Label Position Inverter with a small capacity (15kW or lower) Inverter with a middle capacity (18.5kW or higher) 0-5

7 Warning Label Position for Inside the Inverter 0-6

8 Compliance with UL/cUL Standards 1. Overview The UL standard is an abbreviation for Underwriters Laboratories Inc. and is a safety standard for preventing fires and other accidents, and protecting users, servicemen, and general people in the United States. The cul standard is a standard which the UL constituted to meet the CSA standard. Products approved by the cul standard are as valid as produces approved by the CSA standard. 2. Notes See the following notes when you use your inverters as UL/cUL approved products. CAUTION for UL/cUL requirements Hazard of electrical shock. Disconnect incoming power before working on this control. Dangerous voltage exists until charge lights is off. More than one live circuit. Use 60/75 or 90 copper wire only. A Class 2 circuit wired with class1 wire. Field wiring connection must be made by a UL Listed and CSA Certified closed-loop terminal connector sized for the wire gauge involved. connector must be fixed using the crimp tool specified by the connector manufacturer. Connect the power supply to main power supply terminals via the Molded-case circuit breaker(mccb) or the earth leakage circuit breaker(elcb) to apply the UL Listing Mark. (See Instruction Manual basic connection diagram Fig.2-3-1). In case of using auxiliary control-power input (R0,T0), connect it referring to Instruction Manual Basic connection diagram Fig Solid state motor overload protection is provided in each model. See Users Manual : MHT263 for details. 0-7

9 Tightening torque and wire range /75 copper wire CT/HT Use Voltage 3- Phase 200V 3- Phase 400V Inverter type Required torque [lb-inch](n. m) Wire range [AWG] (mm 2 ) Main Auxiliary L1/R,L2/S, P(+),DB, terminal Ground controlpower Control L3/T U,V,W P1,P(+) N(-) FRN VG7S-2/ (2.1) (3.3) 14 (2.1) 14 (2.1) (3.5) (3.5) 8 (8.4) 10 (5.3) 10 (2.1) (13.3) 8 (8.4) (5.3) 7.5 8X2 (8.4X2) 6 (13.3) 6 (13.3) 11 6X2 (13.3X2) 4 (21.2) 4 (21.2) 15 4X2 (21.2X2) 3 (26.7) 12 (3.3) X (26.7) (5.8) (5.8) 3X2 (13.3X2) 10 (26.7X2) 4X2 4X (5.3) (1.2) (0.7) (21.2X2) (21.2X2) 119 2X2 1/0 3X (13.5) (33.6X2) (53.5) (26.7X2) (8.4) 37 1X2 (42.4X2) 3/0(85) 4/0(107.2) /0X2 4/0 1X (13.5) (13.3) (67.4X2) (107.2) (42.4X2) (27) 3/0X2 1/0X2 2/0X (85X2) (53.5X2) (67.4X2) (21.2) 75 2/0X2 3/0X2 4/0X (67.4x2) (85X2) (107.2X2) (33.6) 90 (48) (27) 600 4/0X2 250X2 1 (304) (107.2X2) (127X2) (42.4) (3.3) 14 (2.1) (5.3) 12 (3.3) (2.1) (3.5) (3.5) (8.4) 10 (5.3) (13.3) 8 (5.3) (2.1) (21.2) (8.4) (5.8) (5.8) 3 (26.7) 6(13.3) (13.3) 22 6X2 (13.3X2) 4 (21.2) 4 (21.2) 30 2 (33.6) 3 (26.7) 3 (26.7) 12(3.3) 37 1 (42.4) 2 (33.6) X2 45 (33.6) (5.3) (13.5) (26.7X2) (42.4) (13.5) 2X2 1/0 3X (33.6X2) (53.5) (26.7X2) (8.4) 75 2/0(67.4) 3/0(85) 4/0(107.2) 6 3/0 4/0 1X (13.3) (85) (107.2) (42.4X2) (27) 1X2 1/0X2 1/0X (42.4X2) (53.5X2) (53.5X2) (21.2) /0X2 (177) 3 (203) (85X2) (26.7) 160 (1.2) (0.7) 3/0X2 3/0X2 4/0X2 2 (85X2) (85X2) (107.2x2) (33.6) 200 4/0X2 250X2 300X2 1/0 (107.2X2) (127X2) (152X2) (53.5) X2 300X2 350X2 2/0 (127X2) (152X2) (177X2) (67.4) X2 400X2 250X3 280 (27) (203X2) (203X2) (127X3) 3/ X3 250X3 300X3 (85) (48) (127X3) (127X3) (152X3) X2 600X2 400X3 (304X2) (304X2) (203X3) X3 350X3 500X3 250 (177X3) (177X3) (253X3) (127) X3 (253X3) X3 (253X3) 500X3 (253X3) 600X4 (304X4) 500X4 (253X4) 350(177) Auxiliary controlpower 16 (1.3) 16 (1.3) Control 24 (0.2) 24 (0.2) 0-8

10 VT Use Inverter type Required torque [lb-inch](n. m) Wire range [AWG] (mm 2 ) Voltage FRN Main Auxiliary L1/R,L2/S, P(+),DB, Ground VG7S-2/4 terminal control- Control U,V,W P1,P(+) L3/T N(-) power (2.1) (3.3) (2.1) (2.1) (8.4) 10 (5.3) (3.5) (3.5) 6 (13.3) 8 (8.4) (5.3) (2.1) 5.5 8X2 (8.4X2) 6 (13.3) 6 (13.3) 7.5 6X2(13.3X2) 8X2(8.4X2) 10X2(5.3X2) 11 4X2 (21.2X2) 3 (26.7) 3 (26.7) 12 (3.3) X2 6X2(13.3X2) 6X2(13.3X2) (5.8) (5.8) (26.7X2) 4X2(21.2X2) 4X2(21.2X2) (5.3) X2(26.7X2) 3X2(26.7X2) 3X2(26.7X2) 8(8.4) Phase 1X2 2X2 2X2 30 (13.5) (1.2) (0.7) 200V (42.4X2) (33.6X2) (33.6X2) 6 (13.3) /0X2 (67.4X2) 4/0 (107.2) 1X2 (42.4X2) (13.5) 3/0X2 1/0X2 2/0X2 4 (27) (85X2) (53.5X2) (67.4X2) (21.2) 55 2/0X2 3/0X2 4/0X2 2 (67.4X2) (85X2) (107.2X2) (33.6) /0 (107.2X2) 4/0X2 (107.2X2) 250X2 (127X2) 1 90 (48) (27) 250X2 300X2 350X2 (42.4) (127X2) (152X2) (177X2) (5.3) 12 (3.3) 14 (2.1) (3.5) (3.5) 8 (8.4) 10 (5.3) (13.3) 8 (5.3) (21.2) (8.4) 6 (2.1) (26.7) 6 (13.3) (13.3) 18.5 (5.8) (5.8) 6X2 4 (21.2) 4 (21.2) 22 (13.3X2) 3 (26.7) 3 (26.7) 12 (3.3) 30 1 (42.4) 2 2 (33.6) X2(26.7X2) (33.6) 1 (42.4) (5.3) 45 (13.5) 119 (13.5) 2X2(33.6X2) 1/0(53.5) 3X2(26.7X2) 8(8.4) 55 3X2(26.7X2) 2X2(33.6X2) 2X2(33.6X2) /0(85) 4/0(107.2) 1X2(42.4X2) (13.3) 1X /0X2 1/0X2 4 (27) (42.4X2) (53.5X2) (53.5X2) (21.2) 1/0X2 2/0X2 3/0X (53.5X2) (67.4X2) (85X2) (26.7) 3/0X2 3/0X2 4/0X (85X2) (85X2) (107.2X2) (33.6) /0X2 250X2 300X2 1/0 Phase 160 (1.2) (0.7) (107.2X2) (127X2) (152X2) (53.5) 400V 250X2 300X2 350X2 2/0 200 (127X2) (152X2) (177X2) (67.4) X2 400X2 500X2 3/0 (177X2) (203X2) (253X2) (85) X2 400X2 400X3 250 (27) (203X2) (203X2) (203X3) (127) /0X3 250X3 300X3 3/0 (48) (107.2X3) (127X3) (152X3) (85) X3 300X3 400X3 (152X3) (152X3) (203X3) X3 350X3 500X3 250 (177X3) (177X3) (253X3) (127) X3 600X3 600X3 (253X3) (304X3) (304X3) X3 500X3 500X4 (253X3) (253X3) (253X4) X4 500X4 600X4 (253X4) (253X4) (304X4) 350(177) Auxiliary controlpower Suitable for use on a circuit capable or delivering not more than 42,000 rms symmetrical amperes, 230V maximum rated for 200V class input. Suitable for use on a circuit capable or delivering not more than 42,000 rms symmetrical amperes, 480V maximum rated for 400V class input. Connect power supplies described in the following table as the input power supply for your inverters. (short circuit standard) Inverter model Maximum input voltage Input power supply current FRN0.75VG7S-2 - FRN90VG7S-2 AC230V 42,000A or less FRN3.7VG7S-4 - FRN400VG7S-4 AC480V FRN710BVG7S-4DC,FRN800BVG7S-4DC AC460V 100,000A or less 16 (1.3) 16 (1.3) Control 24 (0.2) 24 (0.2) 0-9

11 2. 90 copper wire CT/HT Use Inverter type Required torque [lb-inch](n. m) Wire range [AWG] (mm 2 ) Voltage FRN Main Auxiliary L1/R,L2/S, P(+),DB, VG7S-2/4 terminal Ground controlpower Control L3/T U,V,W P1,P(+) N(-) (2.1) (2.1) 14 (2.1) 3.7 (3.5) (3.5) 10 (5.3) (8.4) 10 (5.3) 12 (3.3) (13.3) 8 (8.4) 8 (8.4) 14 (2.1) 11 3 (26.7) 6 (13.3) 6 (13.3) 15 6X2 4 (21.2) (21.2) 18.5 (13.3X2) (5.8) (5.8) 3 (26.7) 4X2 6X2 6X (21.2X2) (13.3X2) (13.3X2) Phase 119 3X2 1 1/ (1.2) (0.7) 200V (13.5) (26.7X2) (42.4) (53.5) (5.3) 37 4/0 2/0 3/0 119 (107.2) (67.4) (85) (13.5) 1/0X2 3/0 4/0 (8.4) (27) (53.5X2) (85) (107.2) 55 2/0X2 1X2 1/0X2 6 (67.4X2) (42.4X2) (53.5X2) (13.3) /0X (177) (203) (85X2) (21.2) 90 (48) (27) /0X2 2 (253) (304) (107.2X2) (33.6) (2.1) (3.3) (3.5) (3.5) (5.3) 14 (2.1) 14 (2.1) 11 8 (8.4) 12 (3.3) 10 (5.3) (13.3) 8 (8.4) 18.5 (5.8) (5.8) 8 (8.4) 14 (2.1) 22 4 (21.2) 6 (13.3) 6 (13.3) 30 3 (26.7) 4 (21.2) 37 2 (33.6) 4 (21.2) 3 (26.7) (13.5) 1/0 (53.5) 2 (33.6) 2 (33.6) 12 (3.3) (13.5) 4X2 1 1/ (21.2X2) (42.4) (53.5) (5.3) 75 1/0 (53.5) 2/0 (67.4) 3/0 (85) /0 (85) 3/0 (85) 4/0 (107.2) (8.4) 110 (27) 4/0 1X2 1X2 6 (107.2) (42.4X2) (42.4X2) (13.3) (127) 300 (152) 400(203) /0X2 160 (21.2) (203) (203) (85X2) Phase X (1.2) (0.7) 400V (304) (304) (127X2) (42.4) 220 4/0X2 4/0X2 300X2 1/0 (107.2X2) (107.2X2) (152X2) (53.5) X2 400X2 400X2 (203X2) (203X2) (203X2) X2 350X2 400X2 2/0 280 (27) (152X2) (177X2) (203X2) (67.4) X2 400X2 500X2 315 (48) (177X2) (203X2) (253X2) X2 500X2 300X3 (253X2) (253X2) (152X3) X2 600X2 400X3 4/0 (304X2) (304X2) (203X3) (107.2) X3 300X3 500X3 (152X3) (152X3) (253X3) X3 500X3 600X3 (253X3) (253X3) (304X4) 350(152) X4 800 (253X4) Auxiliary controlpower 16 (1.3) 16 (1.3) Control 24 (0.2) 24 (0.2) 0-10

12 VT Use Inverter type Required torque [lb-inch](n. m) Wire range [AWG] (mm 2 ) Voltage FRN Main Auxiliary L1/R,L2/S, P(+),DB, Ground VG7S-2/4 terminal control- Control U,V,W P1,P(+) L3/T N(-) power (2.1) 14 (2.1) 14 (2.1) (5.3) 3.7 (3.5) (3.5) 8 (8.4) 10 (5.3) 12 (3.3) (13.3) 8 (8.4) 8 (8.4) X2(8.4X2) 6(13.3) 6(13.3) (2.1) 11 6X2 4 4 (21.2) 15 (13.3X2) (21.2) 3 (26.7) X2 6X2 (5.8) (5.8) (21.2X2) 6X2 (13.3X2) Phase (1.2) (0.7) (26.7X2) (21.2X2) (5.3) 200V 119 2X2 4x2 3X (13.5) (33.6X2) (21.2x2) (26.7X2) (8.4) 37 1/0X2(53.5X2) 3/0(85) 4/0(107.2) 119 2/0X2 1x2 1/0X (13.5) (27) (67.4X2) (42.4x2) (53.5X2) (13.3) 1/0X2 2/0X2 3/0X (53.5X2) (67.4X2) (85X2) (21.2) 3X2 (13.3X2) 4X /0X2 (85X2) 3/0X2 (85X2) 4/0X2 (107.2) 2 90 (48) (27) 4/0X2 4/0X2 300X2 (33.6) (107.2X2) (107.2X2) (152X2) (3.3) (2.1) 14 (2.1) 5.5 (3.5) (3.5) 10 (5.3) (8.4) 12 (3.3) 10 (5.3) (13.3) 8 (8.4) (8.4) (2.1) 18.5 (5.8) (5.8) 4 (21.2) 6 (13.3) 6 (13.3) 22 3 (26.7) 4 (21.2) 30 2 (33.6) 4 (21.2) 3 (26.7) 37 1/0 (53.5) 2 (33.6) 2 (33.6) 12 (3.3) (13.5) 119 4X2(21.2X2) 1(42.4) 1/0(53.5) 10(5.3) (13.5) 1/0 4X2 3X (53.5) (21.2X2) (26.7X2) (8.4) 75 3/0(85) 3/0(85) 4/0(107.2) X2 1X2 6 4/0(107.2) (27) (42.4X2) (42.4X2) (13.3) 1X2 1/0X2 2/0X2 110 (42.4X2) (53.5X2) (67.4X2) /0X2 (21.2) (203) (203) (85X2) Phase 160 (1.2) (0.7) 400V 3/0X2 (85X2) 4/0X2 250X2 (127X2) 1 (42.4) 200 4/0X2 (107.2X2) 300X2 1/0 (107.2X2) (152X2) (53.5) X2 350X2 400X2 2/0 (152X2) (177X2) (203X2) (67.4) 400X2 300X3 4/ (27) (203X2) 400X2 (152X3) (107.2) 350X2 (203X2) 250X3 2/ (48) (177X2) (127X3) (67.4) 315 4/0X3 250X3 300X3 (107.2X3) (127X3) (152X3) X2 600X2 400X3 4/0 (304X2) (304X2) (203X3) (107.2) X3 500X3 600X3 (203X3) (253X3) (304X3) X3 500X3 600X3 (253X3) (253X3) (304X4) X3 600X3 500X4 (304X3) (304X3) (253X4) 300(152) Auxiliary controlpower Suitable for use on a circuit capable or delivering not more than 42,000 rms symmetrical amperes, 230V maximum rated for 200V class input. Suitable for use on a circuit capable or delivering not more than 42,000 rms symmetrical amperes, 480V maximum rated for 400V class input. Connect power supplies described in the following table as the input power supply for your inverters. (short circuit standard) Inverter model Maximum input voltage Input power supply current FRN0.75VG7S-2 - FRN90VG7S-2 AC230V 42,000A or less FRN3.7VG7S-4 - FRN400VG7S-4 AC480V FRN710BVG7S-4DC,FRN800BVG7S-4DC AC460V 100,000A or less 16 (1.3) 16 (1.3) Control 24 (0.2) 24 (0.2) 0-11

13 Compliance with European Standard The CE marking presented on Fuji products is related to the Council Directive 89/336/EEC and the Low Voltage Directive 73/23/EEC for the Electromagnetic Compatibility (EMC) in Europe. Compliant standards EN : 1997 EN 50178: 1997 Only the models in the 400V series comply with the standards above among the "FRENIC5000 VG7S" series. The 200V series do not conform to the standards. Please note that products of the CT/HT use 18.5 kw and the VT use 22 kw do not comply with the standards, and if you need to use compliant products, you should use the products of the CT/HT use 22 kw and the VT use 30 kw which are models with larger capacities by one grade. 1. Compliance with Low Voltage Directive 1-1 Overview Inverters are subject to the Low Voltage Directive in Europe. Fuji has obtained an approval for the compliance from a European inspection organization, and voluntarily declares the compliance with the Low Voltage Directive. 1-2 Notes See the notes below when you use the inverters in your products compliant with the Low Voltage Directive in Europe. The contact capacity for the alarm relay output (30A, B, C) and the relay signal output (Y5A, Y5C) is DC 48V, 0.5A. Connect your inverter to the ground securely. Connect a ring terminal to a wire when you attach it to the main circuit and inverter ground terminals. Use an independent wiring for the inverter ground terminal G. (Do not connect two or more wires) When you use an earth leakage breaker (RCD), you can use only the Type B for protection for the power supply. Also you should use a transformer for double insulation or reinforced insulation to insulate your inverter from the power supply. Use a molded case circuit breaker (MCCB) and a magnetic contactor (MC) compliant with the EN or IEC standard. For a power supply system (I-T NET) where a neutral point is not grounded, the control terminals are provided as basic insulation in respect to the main circuit. When a person may touch them directly, you should add an external insulation circuit for double insulation. Use your inverter under a condition corresponding to the overvoltage category III and the pollution degree 2 or more prescribed in the IEC664. Install your inverter in a control panel (IP54 or more) with a structure preventing water, oil, carbon and dusts from entering for meeting the pollution degree 2 or more. Use a wire with the diameter and the type prescribed in the Appendix C of the EN for the input/output wiring for your inverter. When you install an external heatsink which is a heatsink for inverter external to the control panel, you should install a protection cover preventing a capacitor and a breaking resistor installed on the heatsink from being touched. When you install an optional AC reactor, a DC reactor, and an external braking resistor, follow the description below to prevent an electric shock due to touching the terminals and active electrical parts. 1) Install them in a casing or wall of the IP4X when a person may have an easy access to them. 2) Install them in a casing or wall of the IP2X when a person does not have an easy access to them. 0-12

14 Table 1-2 Applicable main circuit motor/wire size for compliance to Low Voltage Directive(400V series) Fuse/MCCB Rated current [A] Tightening torque [N.m] Recommended wire size [mm 2 ] Voltage Applicable motor KW Inverter type FRN With DCR Without DCR L1/R,L2/S,L3/T U,V,W P1,P(+),DB,N(-) zg R0,T0 Controller L1/R,L2/SL3/T (zg) With DCR Without DCR U,V,W R0,T0 P1,P(+) P(+),DB,N(-) Controller 400V series VG7S-4(CT/HT) VG7S-4(VT) (2.5) VG7S-4(CT/HT) (4) VG7S-4(VT) VG7S-4(CT/HT) (6) (4) VG7S-4(VT) VG7S-4(CT/HT) (4) (10) 15 11VG7S-4(VT) VG7S-4(CT/HT) 5.8 (6) (16) VG7S-4(VT) 22 22VG7S-4(CT/HT) (16) 30 22VG7S-4(VT) X VG7S-4(CT/HT) (16) (16) 37 30VG7S-4(VT) VG7S-4(CT/HT) (16) (25) 45 37VG7S-4(VT) X VG7S-4(CT/HT) (25) (25) 55 45VG7S-4(VT) X2 25X2 25X VG7S-4(CT/HT) (25) (35) 75 55VG7S-4(VT) X2-35X2 35X VG7S-4(CT) (35) VG7S-4(VT) X2 50X VG7S-4(CT) (50) VG7S-4(VT) X2-50X2 70X VG7S-4(CT) (50) VG7S-4(VT) X2-70X X VG7S-4(CT) to VG7S-4(VT) X X VG7S-4(CT) (120) VG7S-4(VT) X2 150X VG7S-4(CT) 120X VG7S-4(VT) (120) - 150X2 185X VG7S-4(CT) VG7S-4(VT) X2-240X2 240X VG7S-4(CT) (185) VG7S-4(VT) X2-240X2 185X VG7S-4(CT) (240) VG7S-4(VT) X2-150X3 185X VG7S-4(CT) (240) 300X VG7S-4(VT) 1, X3-185X3 240X VG7S-4(CT) (300) VG7S-4(VT) 1, X3-300X3 300X ~ 0.75 Note: The used wires are 600V PVC insulated electric wire with permissible temperature of 70 C. This wire is selected assuming that the ambient temperature is 50 C or less. 0-13

15 Contents Instructions Safety Instructionss 1. Before Use Inspection After Receipt External View of the Product Handling of the Product Transportation Storage Explanation of New Model Motor Applicable Motor Model Motor Selection About the SX bus, CC-Link, and the Fieldbus Option Installation and Connection Operating Conditions Installation Procedure Electric Connections Basic Connections Wiring of Main Circuit and Grounding Terminals Wiring of Control Terminals Terminal Arrangement Chart Test Run Preliminary Check and Preparation Operating Methods Test Run Maintenance and Inspection Daily Inspection Periodical Inspection Measurement of Main Circuit Electrical Quantity Insulation Test Parts Replacement Inquiries about Products and Product Guarantee Compliance with Standards Compliance with UL/cUL Standards Overview Notes Compliance with European Standard Compliance with Low Voltage Directive Overview Notes Compliance with EMC standard Overview RFI Filter Recommended Installation KEYPAD Panel Appearance of KEYPAD Panel Alarm Mode KEYPAD Operation System (Hierarchical Structure of LCD Screens) During Normal Operation When an Alarm Raised Occurs Program Mode Function Selection List of Inverter Protective Functions Function Description (Arranged by Function) If You Think Defective If You Think Defective What You Should Check First Checks Using Flowchart Malfunctions not Followed by Alarms Malfunctions Followed Alarms

16 1. Before Use 1-1 Inspection After Receipt Unpackage the product and perform the following checks. If the product is found to have a fault, please contact the dealer from which you purchased the product or the nearest sales office of Fuji Electric. (1) Read the nameplate to check that the product is the same thing as ordered. TYPE : Inverter type FRN 30 VG7S - 4 Voltage class: 2 for 200V or 4 for 400V Series name: VG7S Applicable motor capacity: 30 for 30kW Model :FRENIC5000 Nameplate SOURCE : Power ratings OUTPUT : Rated output MASS : Mass SER.No. : Serial No. 4 3 HH12345R H Product No. Serial lot No. Month of manufacture:1 to 9 for January to September, X for October, Y for November,or Z for December Year of manufacture:last digit of A.D. (4 for 2004) (2) Check for broken or missing parts and damage caused to the cover/body during transportation. Do not energize a product with broken or missing parts or damaged during transportation. Doing so may lead to electric shock or fire. 1-2 External View of the Product 15kW or lower 18.5~400kW 1-1

17 Surface cover fixing screws Lifting holes (Six in total) KEYPAD panel Waring label Surface cover Nameplate 500kW or higher 1-3 Handling of the Product (1) Removal of Surface Cover Loosen the surface cover fixing screws. Remove the cover by pulling the top of the cover as shown in Figure Figure Removal of Surface Cover (15kW or lower) Remove the six surface cover fixing screws. Remove the surface cover. Figure Removal of Surface Cover (18.5~400kW) 1-2

18 Please loosen the surface cover installation screw, and detach the surface cover. Please execute detaching the surface cover (inside) after moving the closing board under the touch panel to the lower side as shown in a lower right picture. A fixed screw of the closing board under the touch panel is loosened. The closing board is moved downward. Surface cover (middle) Figure Removal of Surface Cover (500kW or higher) (2) Removal of KEYPAD Panel After removing the face cover in step (1), loosen the KEYPAD panel fixing screws. Remove the KEYPAD panel as shown in Figure Figure Removal of KEYPAD Panel (15kW or lower) Loosen the KEYPAD panel fixing screws. Carefully remove the KEYPAD panel with your fingers inserted to the cutouts at the side of the KEYPAD panel. Careless handling may break connectors. Figure Removal of KEYPAD Panel (18.5kW or higher) 1-3

19 1-4 Transportation Always hold the body during transportation. Do not hold the cover or any other part. Doing so may break or fall the product. When using a hoist or crane to transport a product with lifting holes, hang hooks and ropes to the holes. 1-5 Storage Temporary Storage Store the product under the conditions specified on Table Table Storage Conditions Item Ambient temperature 10 to +50 C See Note 1 Storage temperature 25 to +65 C Relative humidity 5% to 95% Atmosphere See Note 2 Requirement No condensation or freezing should occur due to sudden temperature changes. The product should not be exposed to dust, direct sunlight, corrosive or combustible gas, oil mist, vapor, waterdrops, vibration, or air containing much salt. Note 1: The storage temperature applies to the temporary storage during transportation, for example. Note 2: Do not store the product in a place where the temperature significantly changes as this may cause condensation or freezing even if the humidity requirement is satisfied. (1) Do not place the product directly on the floor. (2) Pack the product with a plastic sheet or such if stored under undesirable conditions. (3) Seal in a desiccative such as silica gel when packing the product if it may be affected by moisture. Extended Storage The requirements to be satisfied when storing the product for an extended period after purchased greatly depend on the environment. General requirements are listed below. (1) Satisfy the requirements for temporary storage. If the storage period exceeds three months, the ambient temperature should be kept below 30 C to protect the dead electrolytic capacitor from deterioration. (2) Carefully pack the product to prevent the intrusion of moisture, etc. Seal in a desiccant to keep the relative humidity inside the pack below 70%, as a guide. (3) The product will be often exposed to moisture or dust if left mounted on a unit or console, especially in a building under construction. In such a case, remove the product and relocate in a well-conditioned place. The electrolytic capacitor will be deteriorated if left dead for an extended period. Do not leave it dead for a period exceeding a year. 1-4

20 1-6 Explanation of New Model Motorp Applicable Motor Model A part of electric constant of a standard motor was changed in capacity along with the product improvement of the motor (eight types and nine type series). Should it suit to the change of a standard motor, and the motor constant parameter of the inverter also change. In a standard motor of the VG7S series, it is the following capacity that an electric constant changes. Motor model Inverter model Capacity (kw) 200V series 400V series Motor production company MVK8187A FRN30VG7S-2/4 30 Fuji Electric Motor Co.,Ltd. MVK9224A FRN55VG7S-2/4 55 MVK9254A FRN75VG7S-2/4 75 MVK9256A FRN90VG7S-2/4 90 MVK9284A FRN110VG7S MVK9286A FRN132VG7S MVK931LA FRN160VG7S MVK931MA FRN200VG7S MVK931NA FRN220VG7S No change 1-5 Changed Changed Japan Motor & Generator Co,Ltd. We will set the constant suitable for a new motor when shipping it about VG7S of the above-mentioned capacity. On the other hand, a set value is the same as the current in capacity other than the above-mentioned because it doesn't change of an electric constant. Change P02 "M1 motor selection" to the old motor corresponding when you drive the old model motor Motor Selection An automatic setting of a new motor can be done by P02 "M1 motor selection" in the main body software and the KEYPAD panel shown in the table below. Corresponding software (ROM) KEYPAD number RFVG7-H10075 or more RFVG7-H20075 or more K0051 or more If "Capacity (kw) - voltage (2,4)" is selected, the optimal value of new standard motor is automatically written in F04, F05, and P03 to P27. Because F04, F05, and P03 to P27 need not be changed, these codes are writeprotected. Please assume P02 to be "OTHER", and set it to F04, F05, and P03 to P27 individually in old software. Refer to the VG7S user's manual about a set value of motor constant function (F04,F05, and P03 to P25). Old New 00: : : : : : 45-4Y 01: : 45-4Y 02: : 45-4S 02: : 45-4S 03: : : : 55-4 Old: MVK9250A 04: : : : 75-4 Old: MVK9252A 05: : : : 90-4 Old: MVK9280A 06: : : : Old: MVK9282A 07: : : : Old: MVK9310A 08: : : : Old: MVK9312A 09: : : : Old: MVK9316A 10: : : 30-2 Old: MVK6206A 35: Old: MVK9318A 11: : P-OTR 11: : P-OTR 12: 45-2Y 37: OTHER 12: 45-2Y 37: OTHER 13: 45-2S 13: 45-2S 38: 30-2A New: MVK8187A 14: : 55-2 Old: MVK9250A 39: 55-2A New: MVK9224A 15: : 75-2 Old: MVK9252A 40: 75-2A New: MVK9254A 16: : 90-2 Old: MVK9280A 41: 90-2A New: MVK9256A 17: : : 30-4A New: MVK8187A 18: : : 55-4A New: MVK9224A 19: : : 75-4A New: MVK9254A 20: : : 90-4A New: MVK9256A Added 21: : : 110-4A New: MVK9284A 22: : : 132-4A New: MVK9286A 23: : : 160-4A New: MVK931LA 24: : 30-4 Old: MVK6206A 49: 200-4A New: MVK931MA 50: 220-4A New: MVK931NA

21 1-7 About the SX bus, CC-Link, and the Fieldbus Optionp SX bus option (OPC-VG7-SX) and CC-Link option (OPC-VG7-CCL) and fieldbus option (DeviceNet: OPC-VG7-DEV,Profibus-DP:OPC-VG7-PDP) are installed and used, it should be the following inverter model. (The order June, 2006 back. ) Option Inverter model Installed software (ROM) Option card that cannot be installed OPC-VG7-UPAC, SX bus option FRN VG7S-2SX RFVG7-H1E0 OPC-VG7-CCL, OPC-VG7-DEV, (OPC-VG7-SX) FRN VG7S-4SX RFVG7-H2E0 OPC-VG7-SIU, OPC-VG7-PDP, OPC-VG7-RS CC-Link option (OPC-VG7-CCL) FRN VG7S-2CC FRN VG7S-4CC RFVG7-H1CC RFVG7-H2CC OPC-VG7-TL, OPC-VG7-SX, OPC-VG7-DEV, OPC-VG7-PDP Fieldbus option (DeviceNet:OPC-VG7-DEV, Profibus-DP:OPC-VG7-PDP) FRN VG7S-2FB FRN VG7S-4FB RFVG7-H110C RFVG7-H210C OPC-VG7-TL, OPC-VG7-CCL, OPC-VG7-SIU, OPC-VG7-UPAC, OPC-VG7-SX Please note that each option cannot be used by the models other than the above-mentioned like a standard model (FRN VG7S-2 or FRN VG7S-4) etc. (Special type are excluded.) Moreover, please note that the option card described to a right column cannot be installed in the above-mentioned each inverter model. However, there is a product that can use the above-mentioned option in a standard model (SX, CC, FB none FRN VG7S-2 or FRN VG7S-4 of the type end) in a former product..the order in May, , too. Whether it uses it can be confirmed by inverter software (ROM) No.. Option SX bus option (OPC-VG7-SX) CC-Link option (OPC-VG7-CCL) Fieldbus option (DeviceNet:OPC-VG7-DEV, Profibus-DP:OPC-VG7-PDP) Software that can be used (ROM) RFVG7-H1E0 RFVG7-H2E0 RFVG7-H1CC RFVG7-H2CC RFVG7-H110C RFVG7-H210C Option card that cannot be installed OPC-VG7-UPAC, OPC-VG7-CCL, OPC-VG7-DEV, OPC-VG7-SIU, OPC-VG7-PDP, OPC-VG7-RS OPC-VG7-TL, OPC-VG7-SX, OPC-VG7-DEV, OPC-VG7-PDP OPC-VG7-TL, OPC-VG7-CCL, OPC-VG7-SIU, OPC-VG7-UPAC, OPC-VG7-SX (note) Software No. is possible to confirm it by "5. maintenance" of keypad panel. 1-6

22 2. Installation and Connection 2-1 Operating Conditions Install the product under the conditions specified in Table Table Operating Conditions Item Requirement Place Indoor Ambient 10 to +50 C temperature Relative humidity 5% to 95% (no condensation allowed) Atmosphere The product should not be exposed to dust, direct sunlight, corrosive gas, oil mist, vapor, waterdrops, or air containing much salt. No condensation should occur due to sudden temperature changes. Altitude 1,000m or less (if more than 1,000m, see Table 2-1-2) Vibration 2 to 9Hz: 3mm amplitude 9 to 20Hz: 9.8m/s 2 (or 2m/s 2 for 200V, 75kW or higher and 400V, 90kW or higher inverters) 20 to 55Hz: 2m/s 2 55 to 200Hz: 1m/s 2 Table Output Reduction Rates at Higher Altitudes Altitude Output Current Reduction Rate 1,000m or less ,000-1,500m ,500-2,000m ,000-2,500m ,500-3,000m

23 2-2 Installation Procedure (1) Install the product onto a rigid structure in the vertical direction with the letters, FRENIC5000 VG7S, seen from the front and fix with specified bolts. Do not install upside down or in the horizontal direction. Failure to do so may lead to injury. (2) The inverter generates heat during operation. Reserve a space as shown in Figure to ensure a sufficient flow of cooling air. The heat is radiated from the top. Do not install the inverter under any unit susceptible to heat. Figure (3) The cooling fins (heat sink) are heated to almost 90 C during operation of the inverter. The inverter mounting surface should be made of a material capable of withstanding this temperature rise. The fins may burn your skin. Install the inverter onto an incombustible material such as metal. Failure to do so may lead to fire. (4) When storing the inverter in a control panel, for example, sufficiently ventilate the inverter so that its ambient temperature will not exceed the specified limit. Do not store the inverter in a small closed box that does not radiate heat well. (5) When storing two or more inverters in a unit or control panel, they are desirably arranged side by side to minimize the thermal effect on each other. If they are inevitably arranged with one above another, separating plate should be provided to prevent the heat transfer from the bottom side inverter to the above. (6) The inverter is prepared to be mounted in a control panel when delivered. It may be externally cooled using the optional adapter if 15kW or lower or with the mounting legs relocated if 18.5kW or higher. With the inverter externally cooled, the heat generated inside the unit or control panel is dissipated because the cooling fins, which radiate 70% of the generated heat, are excluded from the unit or control panel. Do not exclude the cooling fins where they may be clogged with lint or damp dust. Figure External Cooling System Do not admit lint, paper, wooden chips, dust, metallic pieces, and any other foreign matters into the inverter or allow them to stick to the cooling fins. Doing so may lead to fire or accident. 2-2

24 To externally cool a for 18.5kW to 630kW inverter, relocate the upper and lower mounting legs as shown in Figure Remove the mounting leg fixing screws, relocate the legs, and fix with casing fixing screws. (The casing fixing screws cannot be directly used for some models. See the following table.) The mounting leg fixing screws become unnecessary after the legs are relocated. Voltage class 200V 400V Number and Size of Fixing Screws Inverter model Mounting leg fixing Casing fixing screws screws FRN18.5VG7S-2~FRN55VG7S-2 5 (M6 20) 5 (M5 16) FRN75VG7S-2 7 (M6 20) 5 (M5 16) FRN90VG7S-2 6 (M6 20) 6 (M5 16) FRN18.5VG7S-4~FRN75VG7S-4 5 (M6 20) 5 (M5 16) FRN90VG7S-4~FRN110VG7S-4 7 (M6 20) 5 (M5 16) Note 1 FRN132VG7S-4~FRN160VG7S-4 7 (M6 20) 7 (M5 16) FRN200VG7S-4~FRN250VG7S-4 6 (M6 20) 6 (M5 16) Note 1 FRN280VG7S-4~FRN315VG7S-4 Note 3 6 (M8 20) FRN355VG7S-4~FRN630VG7S-4 Note 3 8 (M8 20) Note 2 Do not use any screws other than specified. Doing so may lead to fire or accident. Note 1: Fix the legs with M5 20 screws. Note 2: Fix the legs with leg fixing screws. Note 3: The lower leg becomes unnecessary when the inverter is installed on its bottom. Figure Use the screws provided with the inverter when relocating the mounting legs. Failure to do so may lead to injury. 2-3

25 2-3 Electric Connections Removing the surface cover exposes the terminal blocks. Correctly wire them after reading the following instructions Basic Connections (1) Connect power supply leads to the main circuit power terminals, L1/R, L2/S, and L3/T. Connecting any power supply lead to another terminal may fail the inverter. Check that the supply voltage does not exceed the permissible limit indicated on the nameplate, etc. (2) The grounding terminal must be grounded to prevent disasters such as electric shock and fire and reduce the noise. (3) Use a reliable crimp terminal to connect each lead. (4) After making connections (wiring), check that: 1) leads are correctly connected, 2) all necessary connections are made, and 3) no terminal or wire is short-circuited or grounded. (5) When any connection is changed after the inverter is energized: It takes a long time for the smoothing capacitor in the DC link circuit of the main circuit to be discharged after the power supply is shut off. After the CHARGE lamp goes off, check with a multimeter or such that the DC voltage has been reduced to a safe level (25V DC or less). Short-circuiting a circuit in which a voltage (potential) still remains may generate sparks. Wait until the voltage goes away. Always connect the grounding lead. Failure to do so may lead to electric shock or fire. The wiring work should be performed by qualified persons. Before working, check that the power supply is shut off (open). Failure to do so may lead to electric shock. Do not use any lead size other than specified. Doing so may lead to fire. 2-4

26 Basic Wiring Diagram 1(FRN0.75VG7S-2~FRN90VG7S-2, FRN3.7VG7S-4~FRN630VG7S-4) Figure Basic Wiring Diagram 2-5

27 Basic Wiring Diagram 2(FRN710BVG7S-4DC,FRN800BVG7S-4DC) Figure Basic Wiring Diagram 2-6

28 2-3-2 Wiring of Main Circuit and Grounding Terminals Table Functions of Main Circuit and Grounding Terminals Terminal symbol Terminal name Description L1/R, L2/S, L3/T Main circuit power input terminals Connected with three-phase power source. U, V, W Inverter output terminals Connected with three-phase motor. R0, T0 Auxiliary control power input terminals Connected with the same AC power source as used for main circuit, as back-up power source for control circuit. P1, P(+) DC reactor connecting terminals Connected with (optional) input power-factor correcting DC reactor. P(+), DB Braking resistor connecting terminals Connected with (optional) braking resistor. P(+), N( ) DC link circuit terminals Supplies DC link circuit voltage. Connected with (optional) external braking unit or (optional) power regenerative unit. zg Inverter grounding terminals Grounds inverter chassis (casing). Connected with earth. (1) Main circuit power input terminals (L1/R, L2/S, and L3/T) 1) The main circuit power input terminals, L1/R, L2/S, and L3/T should be connected with the power source via earth-leakage circuit breaker for line protection. Any phase may be connected to any lead. If the zero-phase current is detectable by the upstream system, however, ordinary circuit breakers may be used. 2) Connect a magnetic contactor so that the inverter can be disconnected from the power source to minimize the influence of any failure when the inverter protective function is activated. 3) Do not start or stop the inverter by turning the main power switch on or off. Use the control circuit terminals, FWD and REV, or the FWD, REV, and STOP keys on the KEYPAD panel to start or stop the inverter. When the inverter is inevitably started or stopped using the main power switch, do not turn it on or off more than once per hour. 4) Do not connect any terminal to a single-phase power source. 2-7

29 (2) Inverter output terminals (U, V, and W) 1) Connect three-phase motor leads to the inverter output terminals, U, V, and W with care not to connect a wrong phase. 2) Do not connect a phase advancing capacitor or surge absorber (suppressor) to the inverter output terminals. 3) If the wiring between the inverter and the motor is too long, a high-frequency current will run through the wiring due to floating capacity to trip the inverter because of overcurrent, increase the leakage current, and/or deteriorate the current indication accuracy. Therefore, the motor wiring length should not exceed 50m for 3.7kW or lower inverters or 100m for others, as a guide. Connect the optional output circuit filter (OFL filter) if the wiring is too long. 4) When you use a motor with an encoder, limit the wiring distance between your inverter and motor to 100 m or less. This limit is due to encoder characteristic. When the distance exceeds 100 m, you need an arrangement such as inserting an isolation converter. Without output circuit filter When two or more motors are to be driven, the total length of wirings to those motors should not exceed 50m for 3.7kW or lower inverters or 100m for 5.5kW or higher ones. With output circuit filter When two or more motors are to be driven, the total length of wirings to those motors should not exceed 400m. Note: When a thermal relay is used between the inverter and the motor, especially for 400V series, the thermal relay may malfunction even with a wiring length less than 50m. In this case, connect an OFL filter or reduce the inverter operation noise (carrier frequency) using function code F26 (motor sound (carrier frequency)). Driving a 400V motor with an inverter If a motor is driven with a PWM inverter, the surge voltage generated by switching inverter elements is overlapped as applied to the motor terminals. Especially for 400V motors, the motor insulation may be deteriorated by the surge voltage if the motor wiring is too long. Therefore, any of the following measures should be taken when a 400V motor is to be driven with an inverter. 1) Use a motor with reinforced insulation (all the Fuji Electric's general-purpose motors have reinforced insulation). 2) Connect the optional output circuit filter (OFL filter) to the inverter output terminals. 3) Shorten the wiring between the inverter and the motor as short as possible (to10 to 20m or less). 2-8

30 (3) Auxiliary control power input terminals (R0 and T0) If the magnetic contactor in the power supply circuit to the inverter is turned off (open) when the protection circuit is activated, the inverter control power supply is shut off. As a result, alarm outputs (30A, B, and C) are no longer retained and indications on the KEYPAD panel go away. To prevent this, the same AC voltage as used for the main circuit is applied to the auxiliary control power input terminals, R0 and T0. Although the inverter functions with no voltage applied to these terminals, it is strongly recommended to connect the voltage to R0 and T0 to ensure safe operation. Figure Wiring of Auxiliary Control Power Input Terminals 1) When a radio noise filter is used, the power to be connected to the auxiliary control power input terminals, R0 and T0, should be taken from a point downstream the filter. If it is taken from a point upstream the filter, the noise reduction effect is impaired. (4) DC reactor connecting terminals (P1 and P(+)) 1) These terminals are provided to connect the optional input power-factor correcting DC reactor. A jumper is connected between the terminals before delivery from the factory. Remove the jumper before connecting the DC reactor. 2) Do not remove the jumper when the DC reactor is not used. Note: The DC reactors are (externally) provided as standard equipment for 75kW or higher inverters. Always use the DC reactor for those inverters. Figure ) Connect a DC reactor for an inverter meeting the following conditions and having a rated motor output of 55 kw or less. The capacity ratio between the power transformer and the inverter follows the Figure You connect a thyristor load to the same power supply, or you control to turn ON/OFF a capacitor adjusting power factor. Imbalance of 2% or more exists in power supply. Power supply voltage imbalance rate [% ] Maximum voltage [V] Minimum voltage [V] = x 67 Three-phase average voltage [V] Improving input power factor is intended. Power factor will be improved up to about Power supply transformer capacity [kva] (a)capacity ratio DC reactor required DC reactor not required Inverter capacity [kva]/unit Inverter Figure (b)power supply system Power supply transformer MCCB MCCB MCCB MC Power factor Thyristor adjusting converter capacitor 2-9

31 (5) Braking resistor connecting terminals (P(+) and DB) The optional braking resistor may be externally mounted. It is required when the inverter is operated frequently or under heavy inertia. 1) Connect the braking resistor terminals, P(+) and DB, to the inverter terminals, P(+) and DB. 2) Lay out so that the wiring length will not exceed 5m. The two leads should be twisted or in close contact (parallel). DC reactor (DCR) G Braking resistor DB ZZ P1 P(+) DB N( ) P DB 2 1 (CM) (THR) Figure Connection Diagram (For 200V, 55kW or Lower and 400V, 110kW or Lower Inverters) Do not directly connect the braking resistor to the DC terminals, P(+) and N( ). Doing so may lead to fire. (6) DC link circuit terminals (P(+) and N( )) The 200V series, 75kW or higher and 400V series, 132kW or higher inverters contain no braking resistor drive circuit. When the braking resistor is required, a braking unit should be used. 1) Connect the braking unit terminals, P(+) and N( ), to the inverter terminals, P(+) and N( ). Lay out so that the wiring length will not exceed 5m. The two leads should be twisted or in close contact (parallel). 2) Connect the braking resistor terminals, P(+) and DB, to the braking unit terminals, P(+) and DB. Lay out so that the wiring length will not exceed 10m. The two leads should be twisted or in close contact (parallel). When the inverter terminals, P(+) and N( ), are not used, they should be left open. Never short these terminals or directly connect the braking resistor. Doing so may break the inverter. 3) Auxiliary contacts 1 and 2 of the braking unit have polarity. When connecting a PWM Converter, see the instruction manual for the unit. DC reactor (DCR) G G External braking resistor DB P1 P(+) N( ) P DB P(+)R DB P(+) N( ) 2 1 (CM) 2 1 (THR) Braking unit BU Figure Connection Diagram (200V, 75kW or Higher and 400V, 132kW or Higher Inverters) *More than one braking units or braking resistors may be needed according to a model. For the details of connection, refer to the instruction manual for the braking unit. 2-10

32 (7) Inverter grounding terminals (zg) The inverter grounding terminals, zg, must be grounded to ensure your safety and for noise measures. The Technical Standards for Electric Equipment requires metallic frames of electric equipment be grounded to prevent disasters such as electric shock and fire. Connect the terminals as described below. 1) Connect to type D grounded poles for 200V series or type C grounded poles for 400V series according to the Technical Standards for Electric Equipment. 2) Connect the earth terminal to the dedicated grounding pole of the inverter system using a thick, short lead. Table Voltage class Grounding work class Grounding resistance 200V Type D 100Ω or less 400V Type C 10Ω or less (8) Auxiliary power switching connector (CN UX) (18.5kW or higher) For 18.5kW or higher inverters, if the supply voltage to the main circuit is within the range shown in Table 2-3-3, reconnect the auxiliary power switching connector, CN UX, to U2. For other inverters, leave the connector connected to U1. For details, see Figure Table Voltage Ranges Requiring Reconnection of Auxiliary Power Switching Connector Frequency [Hz] Supply voltage range [ V ] to to 430 Check that the number of phases and rated voltage of the product agree with those of the AC power source. Do not connect any AC power source to the output terminals, U, V, and W. Doing so may lead to injury. (9) Fan power switching connector (CN RXTX) (18.5kW or higher) The VG7S accepts DC power inputs through a common DC terminal without using any optional equipment when combined with a PWM converter as shown in Figure However, 18.5kW or higher inverters contain AC power operated parts such as AC cooling fan. When such DC power inputs are used, reconnect the fan power switching connector, CN RXTX, inside the inverter to R0-T0 as shown in Figure and apply an AC power to the terminals, R0 and T0. For details, see Figure Note: The fan power switching connector, CN RXTX, is normally connected to L1/R-L3/T. Do not reconnect the connector when no DC power inputs are used. Always connect the same AC voltage as used for the main circuit to the auxiliary control power input terminals, R0 and T0. Failure to do so deactivates the fan, which may overheat (OH1) and then fail the inverter. Do not connect the fan power switching connector, CN RXTX, inside the inverter to a wrong terminal. Doing so may fail the inverter. When DC power inputs are used, apply an AC power to R0 and T0 to drive the fan. Failure to do so may fail the inverter. 2-11

33 18.5kW ~ 630kW CN RXTX CN RXTX Figure Reconnection of Fan Power Switching Connector 18.5kW ~ 630kW PWM converter (RHC series) P(+) Earth leakage breaker Power source Magnetic contactor Filter L1/R L2/S L3/T + C N(-) Inverter unit DB P1 P(+) N(-) L1/R L2/S + C U V W M L3/T CN RXTX Fan R0 T0 Reconnect CN RXTX to. R0-T0 Figure An Example of Wiring of Inverter Combined with PWM Converter Note 1: When a 15kW or lower inverter is combined with a PWM converter, do not directly connect any power source to the auxiliary control power input terminals, R0 and T0. If connected to these terminals, the power source should be insulated from the main power supply to the PWM converter with insulating transformer. Examples of wiring of the PWM converter are given in the instruction manual for PWM converter. Note 2: 200V, 75kW or higher and 400V, 132kW or higher inverters contain no braking transistor. 2-12

34 The switching connectors are mounted in the power PC board at the top of the control circuit PC board. CN UX CN RXTX Note: When removing either connector, hold the top of the jaw between fingers to release the latch and remove by pulling upward. When mounting, fully insert the connector and apply the latch until it clicks. FRN18.5VG7S-2 to FRN55VG7S-2 FRN18.5VG7S-4 to FRN110VG7S-4 FRN75VG7S-2 to FRN90VG7S-2 FRN132VG7S-4 to FRN630VG7S-4 CN UX is connected to U1 and CN RXTX to L1/R-L3/T before factory shipment. CN UX : U1 CN RXTX : L1/R-L3/T Figure Power Switching Connectors (18.5kW or Higher Inverters Only) 2-13 The Figure applies when the inverter is used with DC power inputs at a supply voltage of V, 50Hz or V, 60Hz.

35 2-3-3 Wiring of Control Terminals Functions of the control circuit terminals are described in Table Each control terminal should be wired in different ways, depending on its setting. Table Category Terminal symbol Terminal name Function Analog input Digital input 13 Potentiometer power supply Supplies power (+10Vdc) to speed setting POT (1-5kΩ). 12 Voltage input Controls the speed according to the external analog input voltage command. 0 to +10V DC/0 to 100% Reversed operation with ± signals: 0 to ±10V DC/0 to ±100% * Input resistance: 10kΩ 11 Analog input common A common terminal for analog input signals Ai1 Analog input 1 Inputs analog DC voltages between 0 to ±10V DC. For assignment Ai2 Analog input 2 of signals, see 'Functions of Terminals'. * Input resistance: 10kΩ M Analog input common FWD Forward operation command FWD-CM: ON... The motor runs in the forward direction. FWD-CM: OFF... The motor decelerates and stops. REV Reverse operation command REV-CM: ON... The motor runs in the reverse direction. X1 Digital input terminal 1 X2 Digital input terminal 2 X3 Digital input terminal 3 X4 Digital input terminal 4 X5 Digital input terminal 5 X6 Digital input terminal 6 X7 Digital input terminal 7 X8 Digital input terminal 8 X9 Digital input terminal 9 REV-CM: OFF... The motor decelerates and stops. Functions such as external coast-to-stop command, external alarm, alarm reset, and multi-speed control can be turned on or off with terminals X1 to X9. For details, see 'Functions of Terminals'. <Digital Input Circuit Specifications> Item min. typ. max. Operating ON level 0V - 2V voltage OFF level 22V 24V 27V On-time operating current - 3.2mA 4.5mA Off-time permissible leak current mA Analog output PLC PLC signal power supply Connected with output signal power source of PLC (Rated voltage: 24 (22-27)V DC ). CM Digital input common A common terminal for digital input signals AO1 Analog output terminal 1 Outputs monitor signals at analog DC voltages between 0 and ± 10V AO2 Analog output terminal 2 DC. For details of signals, see 'Functions of Terminals'. * Connectable impedance: 3kΩ min. AO3 Analog output terminal 3 M Analog output common 2-14

36 Transistor output Y1 Transistor output 1 Y2 Transistor output 2 Y3 Transistor output 3 Y4 Transistor output 4 Outputs signals such as Running, Speed equivalence, Overload early warning,... and z as transistor outputs from inverter to specified ports. For details, see 'Functions of Terminals'. <Transistor Output Circuit Specifications> Item min. typ. max. Operating ON level - 1V 2V voltage OFF level - 24V 27V On-time max. load current mA Off-time permissible leak current mA Relay output terminals Communication Speed detection Temperature detection CME Transistor output common A common terminal for transistor output terminals. Insulated from terminals CM and A,30B, 30C Alarm relay output (for any fault) Outputs alarm signal as relay contact output (1SPDT) when inverter stops due to alarm. Contact capacity: 250V AC, 0.3A, cos φ = 0.3 (or 48V DC, 0.5A when conformed with Low Voltage Directive) You may choose to close contacts under unusual or normal conditions. Y5A,Y5C Relay output You may select a signal as you may with Y1 to Y4 terminals. Contact capacity is the same as with alarm relay output terminals. RX(+), RX( ) TX(+), TX( ) SD(M) PA,PB RS485 communication input/output Communication shield cable connection Pulse generator 2-phase signal input Input/output terminals for RS485 communication Up to 31 inverters may be connected through multi-drop connections. Terminating resistor (100Ω) can be connected via switch (SW3). Connected with shielded wires. Connected with 2-phase signals from pulse generator PGP,PGM Pulse generator power supply Supplies power (+15V DC (switchable to +12V DC)) to PG. FA,FB Pulse generator output Output pulse generator signal with frequency divided to 1/n. (n is programmable with function code E29.) CM Pulse generator output A common terminal for FA and FB. common TH1,THC NTC/PTC thermistor Monitors motor temperature with NTC and PTC thermistors. For connection terminals PTC thermistor, motor overheat protection level can be set with function code E32. (1) Input terminals (13, 12, and 11) 1) Shielded wires as short as possible (20m or less) should be used for cables because these terminals handle weak analog signals that are very susceptible to external noise. The shields should be grounded to the earth, as a rule. If the signals are greatly affected by external induction noise, however, connecting the shields to terminal 11 may be advantageous. 2) When relay contacts are required in this circuit, use twin contacts handling weak signals. Do not use contacts at terminal 11. 3) If any of these terminal is connected with an external analog signal output unit, it may malfunction due to the noise generated by the inverter, depending on the analog signal output circuit. In this case, connect a ferrite core or capacitor to the external analog signal output unit VR 1k to 5kΩ Figure Figure Protection against Noise (Example)

37 (2) Digital input terminals (FWD, REV, X1-X9, PLC, and CM) 1) The digital input terminals such as FWD, REV, and X1-X9 are generally turned on/off between the CM terminal. If turned on/off using an external power source and open collector outputs from the programmable logic controller, the terminals may malfunction due to current leak from the external power source. In this case, connect the external power source using the PLC terminal as shown in Figure ) When inputs are made through relay contacts, use a highly reliable relay contacts (Fuji Electric's HH54PW control relays, for example). (3) Transistor output terminals (Y1-Y4 and CME) 1) A circuit configuration as shown in the 'Transistor Output Terminals' column of Table is used. Take care not to connect external power leads with reversed polarity. 2) When control relays are used, connect a surge suppression diode to each end of the exciting coil. (4) Miscellaneous Figure Protection against Current Leak from External Power Source 1) The control terminal leads should be kept as apart from the main circuit leads as possible to prevent malfunction due to noise. 2) The control leads inside the inverter should be secured to prevent direct contact with the live part of the main circuit (the main circuit terminal blocks, for example). The shield of each control cable does not serve as a reinforced insulator. If the shield is broken for some reason, a high voltage in the main circuit may invade the control signal circuit. The Low Voltage Directive in Europe also prohibits the users to wire the inverter with a main circuit lead in contact with a control lead. Doing so may lead to electric shock. Noise may be generated from the inverter, motor, and leads. Protect sensors and devices around the inverter from malfunction. Failure to do so may lead to accident. (5) Wiring of Control Circuits 1) FRN18.5VG7S-2 to FRN55VG7S-2 FRN18.5VG7S-4 to FRN110VG7S-4 (a) Pull the wiring out along the left side panel of the inverter as shown in Figure (b) Tie leads with bands (Insulock, for example) and secure to the hole (tie mounting hole A) on the left side wall of the main circuit terminal block on the way outward. The bands should be 3.5mm or less in width and 1.5 mm or less in thickness as they are to be passed through the holes (4mm dia.). (c) If an optional printed circuit board is mounted, secure signal leads to the tie mounting hole B. 2-16

38 Figure Routing Inverter (18.5 kw or Higher) Control Circuit Leads Figure Securing Inverter (18.5 kw or Higher) Control Circuit Leads 2) FRN132VG7S-4 to FRN160VG7S-4 (a) Pull the wiring out along the left side panel as shown in Figure (b) Tie leads with bands (Insulock, for example) and secure with cable tie holders on the beams on the way outward. The bands should be 3.8 mm or less in width and 1.5 mm or less in thickness as they are to be passed through square holes ( ). Figure Routing Inverter Control Circuit Leads Figure Securing Inverter Control Circuit Leads 3) FRN75VG7S-2 to FRN90VG7S-2 FRN200VG7S-4 to FRN250VG7S-4 (a) Pull the wiring out along the left side panel as shown in Figure (b) Tie leads with bands (Insulock, for example) and secure with cable tie holders on the beams on the way outward. The bands should be 3.8 mm or less in width and 1.5 mm or less in thickness as they are to be passed through holes ( ). Figure Routing Inverter Control Circuit Leads Figure Securing Inverter Control Circuit Leads 4) For FRN280VG7S-4 to FRN630VG7S-4 (a) Draw out along the left side panel of your inverter as in the Figure (b) Use an duct of a left board to fix the wiring. 2-17

39 2-3-4 Terminal Arrangement Chart Main circuit terminals FRN VG7S-2 FRN VG7S-4 FRN 37 55VG7S-2 FRN VG7S-4 FRN 11 15VG7S-2 FRN 11 15VG7S-4 FRN 75VG7S-2 FRN VG7S-2 FRN VG7S-4 FRN 90VG7S-2 FRN VG7S-4 FRN 30VG7S-2 FRN 30 55VG7S-4 FRN 280, 315VG7S-4 R0 T0 L1/R L2/S L3/T P1 L1/R L2/S L3/T P1 G z G z U U P(+) P(+) V V W W N(-) N(-) Main circuit terminals FRN 355,400VG7S-4 R0T0 Screw size R0,T0 : M4 G : M10 Other screw size : M12 L1/R L2/S L3/T P1 P(+) N( ) U V W L1/R L2/S L3/T P1 P(+) N( ) U V W Screw size R0,T0 : M4 G : M10 Other screw size : M12 FRN 500,630VG7S-4 G G R0 T0 L1/R L2/S L3/T P(+) P(+) U V W L1/R L2/S L3/T P1 P1 N(-) N(-) U V W is main circuit terminals position. G 2-18 Screw size R0,T0 : M4 G : M10 Other screw size : M12 G

40 FRN 710,800BVG7S-4 N P 2 4 Φ15 N P N P N P Control circuit terminals 4 Φ12 R1 T1 R0 T0 E Screw size : M4 4 Φ12 4 Φ12 AC AC AC IGBT stack U-PHASE IGBT stack V-PHASE IGBT stack W-PHASE 2-19

41 Control circuit terminals Control circuit terminals Screw size : M3 2-20

42 3. Test Run 3-1 Preliminary Check and Preparation Perform the following checks before starting operation. (1) Check that the inverter is correctly wired. Most importantly, the inverter output terminals, U, V, and W should not be connected to a power source and the earth terminal should be correctly grounded. (2) No terminal or exposed live part should be short-circuited or grounded. (3) Check for loose terminals, connectors, and screws. (4) Check that the motor is disconnected from mechanical devices. (5) Turn all switches off so that the inverter will not start or malfunction when powered on. (6) After power-up of the inverter, check that: 1) the KEYPAD panel gives indications as shown in Figure (no alarm message), and 2) the inverter contained fan is rotating. (However, when the function code H06 Cooling fan ON-OFF control is used, there may be a case where the built-in fan is stopped.) z U, V, W Figure Inverter Connection Diagram Figure KEYPAD Panel Display with the Power ON Never turn the power switch on (closed) before mounting the face cover. Do not remove the cover while the inverter is energized. Do not handle the inverter with wet hand. Doing so may lead to electric shock. 3-2 Operating Methods There are many operating methods. Read this manual and select the one most suitable to the intended use and operating conditions. General operating methods are described in Table Test Run After checking that no abnormal condition exists in 3.1, perform a test run. Before delivery, the inverter is programmed to be operated from the KEYPAD panel (with function code F01 set to 0 and F02 to 0). (1) Turn the power on. Check that the speed indicated by blinking LEDs is 0r/min. (2) Set the speed to a lower level around 100r/min using the key. (3) Press the FWD key to run the motor in the forward direction or the REV key to run in the reverse direction. Press the STOP key to stop the motor. (4) Check that: 1) the motor runs in the selected direction (see Figure 3-3-1), 2) it revolves without any problem (motor roars and excessive vibration), and 3) it smoothly accelerates or decelerates. If no abnormal condition is observed, raise the operating speed and check again. If the inverter is found to normally function in the test run, start regular operation. 3-1 Table General Operating Methods Operating Operation Speed controls method commands From KEYPAD panel FWD KEYPAD keys, panel STOP Through external signal input Variable resistor (POT) or analog voltages REV Contact inputs (switches) Terminals: FWD - CM Terminals: REV - CM Figure Motor Rotating Directions